Rack for storing and freezing processed food product

ABSTRACT

A modular rack assembly for storing goods includes a first rack having a base and a plurality of wall portions extending away from the base. Each of the plurality of wall portions is separated from an adjacent of the plurality of wall portions by a space. A lip extends around a perimeter of the base. A second rack is generally identical to the first rack such that, in a first position, the second rack is stackable on top of the first rack such that the first rack engages the base of the second rack in a plane, and the lip of the second rack extends within the plane. A method of transferring heat between atmosphere and chub logs on the rack assembly includes the steps of loading chub logs onto a first rack and then placing a second rack on top of the first rack.

FIELD OF THE INVENTION

The present invention relates to a modular rack assembly for storing food products to enhance the freezing process.

BACKGROUND OF THE INVENTION

Chub is a processed meat product that is formed into logs for sale. To lengthen the life of the chub and to aid in transport to a sales destination, the chub is frozen after manufacturing. Prior to freezing, the chub is typically inserted into boxes, with two chub logs per box. The boxes are stacked onto a pallet and then transported into a freezer. However, due to the volume of chub that is densely packed onto the pallet, as well as the insulating properties of the boxes, it can take up to three days for the chub to fully freeze.

It would be beneficial to be able to stack the chub in a manner that would decrease the freezing time. Further, it would be beneficial to provide a modular system for stacking the chub that can be rearranged to form a smaller volume when the chub is not stacked in the system.

SUMMARY OF THE INVENTION

Briefly, a modular rack assembly for storing goods is provided. The rack assembly comprises a first rack having a base and a plurality of wall portions extending upwardly away from the base. Each of the plurality of wall portions is separated from an adjacent portion of the plurality of wall portions by a relatively flat region. A lip extends around a perimeter of the base. A second rack is generally identical to the first rack. In a first position, the second rack is stackable on top of the first rack such that the first rack engages the base of the second rack in a region of contact defining a plane, and the lip of the second rack extends across the plane.

Further, the present invention provides a modular rack assembly for storing goods. The assembly comprises a first rack having a base and a plurality of wall portions extending upwardly away from the base. Each of the plurality of wall portions is separated from an adjacent portion of the plurality of wall portions by a relatively flat region. A lip extends around a perimeter of the base. A second rack is generally identical to the first rack. In a first position, the second rack is stackable on top of the first rack such that the first rack engages the lip of the second rack.

Additionally, the present invention provides a modular rack assembly for storing goods. The assembly comprises a first rack having a base and a plurality of wall portions extending upwardly away from the base. Each of the plurality of wall portions is separated from an adjacent of the plurality of wall portions by a relatively flat region. Each of the plurality of wall portions includes convex tops. A second rack is generally identical to the first rack. In a first position, the second rack is stackable on top of the first rack such that the convex tops of the first rack engage the base of the second rack.

The present invention also provides a modular rack assembly comprising a first rack having a base and a plurality of wall portions extending upwardly away from the base. Each of the plurality of wall portions is separated from an adjacent portion of the plurality of wall portions by a relatively flat region and wherein each of the plurality of wall portions is tapered from wider at the base to narrower in a direction away from the base. The rack also includes a front end, a rear end, and a plurality of spacer portions extending away from the base between the front end and the rear end. The plurality of spacer portions extend perpendicularly to at least one of the plurality of wall portions. A plurality of concave portions extend between the front end and the rear end and bounded by one or more of the plurality of spacer portions. A lip extends around a perimeter of the base. A second rack is identical to the first rack. In a first position, the second rack is stackable on top of the first rack such that the first rack engages the base of the second rack in region of contact extending in a plane, and the lip of the second rack extends across the plane. Further, the first rack comprises first indicia on at least one of its plurality of wall portions and the second rack comprises second indicia on at least one of its plurality of wall portions such that, in the first position, only one of the first and second indicia is visible from any one direction and, in the second position, both of the first and the second indicia are visible from any one direction.

Also, the present invention provides a method of transferring heat between a product and a surrounding atmosphere comprising the steps of providing a first rack having a base and a plurality of wall portions extending upwardly away from the base. Each of the plurality of wall portions is separated from an adjacent of the plurality of wall portions by a relatively flat region. The first rack also includes a front end, a rear end, a plurality of spacer portions extending away from the base between the front end and the rear end, a plurality of concave portions extending between the front end and the rear end and bounded by one or more of the plurality of spacer portions, and a lip extending around a perimeter of the base. The method further includes the step of loading the plurality of chub logs individually in the plurality of concave regions; placing a second rack, identical to the first rack, on top of the first rack such that the first rack engages the base of the second rack in a region of contact, forming a space between the base of the second rack and the chub logs; and exposing the product to the surrounding atmosphere to transfer heat between the chub logs and the surrounding atmosphere.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description of a desired embodiment of the invention, will be better understood when read in conjunction with the appended drawings, which are incorporated herein and constitute part of this specification. For the purposes of illustrating the invention, there are shown in the drawings embodiments that are presently desired. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. In the drawings, the same reference numerals are employed for designating the same elements throughout the several figures. In the drawings:

FIG. 1 is a perspective view of a rack assembly according to a first embodiment of the present invention, with the rack assembly in a stacked position and product stacked within the assembly.

FIG. 2 is a perspective view of the rack assembly of FIG. 1, with the product removed and the rack assembly in a nested position.

FIG. 3 is a sectional view of the rack assembly of FIG. 1.

FIG. 4 is a sectional view of the rack assembly of FIG. 2.

DETAILED DESCRIPTION OF THE INVENTION

Certain terminology is used herein for convenience only and is not to be taken as a limitation on the present invention. The terminology includes the words specifically mentioned, derivatives thereof and words of similar import. The following describes desired embodiments of the invention. However, it should be understood based on this disclosure, that the invention is not limited by the desired embodiments of the invention.

Referring generally to the figures, several embodiments of a rack assembly for storing a freezing processed meat product, such as chub, are shown. The rack assembly includes a plurality of racks that are each used to store several rolls of chub. In a “use” configuration, the racks are stackable on each other with a volume in between each rack in which chub is stored. In a “storage” configuration, without chub, the racks are able to be nested in each other, generally reducing the volume of the stacked racks and allowing for easier storage and transfer of the racks.

Referring to FIGS. 1-4, a first embodiment of a modular rack assembly 100 is shown. The rack assembly 100 includes a first rack 110 and a second rack 210. While only two racks 110, 210 are disclosed, more than two racks may be used within the spirit and scope of the present invention.

Preferably, the first rack 110 and the second rack 210 are structurally identical. As described herein, the reference numerals for the second rack 210 are the same as for first rack 110 for corresponding elements of the racks 110, 210. As can be seen in FIGS. 1 and 3, when the second rack 210 is stacked on top of the first rack 110 in a first, or stacked, position, a volume 102 is formed between the first rack 110 and the second rack 210 such that a plurality of rolls of chub 104 may be stored within the volume 102. As seen in FIGS. 2 and 4, when the second rack 210 is placed on top of the first rack 110 in a second, or nested, position, the first rack 110 is able to nest in the second rack 210, greatly reducing the volume 102 between the first rack 110 and the second rack 210.

While the intended product to be stored on the racks 110, 210 is rolls of chub 104, those of ordinary skill in the art will recognize that other products may be stored on the racks 110, 210 as well. As can be seen from FIG. 1, in a preferred embodiment, five rolls of chub 104 are able to be stored in the volume 102.

Referring now to FIG. 3, the rack 110 has a base 112 that extends in a first plane 113. The base 112 is generally rectangular in shape, with a first dimension being longer than a second orthogonal dimension. To provide a point of reference, along the longer dimension, one side of the base 112 (visible in FIG. 1) is called the front end 112 a and an opposing side of the base 112 (not visible in FIG. 1) is called the rear end 112 b. The perimeter of the base 112 includes a lip 115 that extends downward from the base 112.

A plurality of wall portions 114 extends along the perimeter of the base 112 and upward from the base 112. Each of the plurality of wall portions 114 is separated from an adjacent of the plurality of wall portions 114 by a relatively flat region 116. Each of the plurality of wall portions 114 is tapered from wider at the base 112 to narrower in a direction away from the base 112. Further, each of the plurality of wall portions 114 preferably includes curved corners and edges, both where each wall portion 114 engages the base 112 and also where each wall portion 114 extends away from the base 112. The corners are curved to reduce stress on the rack 110 and to reduce the possibility of cracking.

A plurality of spacer portions 120 extend from the base 112 between the front end 112 a and the rear end 112 b. Each of the plurality of spacer portions 120 is bounded on at least one side by a relatively flat region 121. The plurality of spacer portions 120 extend perpendicularly to the wall portions 114 that extend along each of the front end 112 a and the rear end 112 b. Each of the plurality of spacer portions 120 is tapered from wider at the base 112 to narrower in a direction away from the base 112. Further, each of the plurality of spacer portions 120 preferably includes curved corners and edges, both where each spacer portion 120 engages the base 112 and also where each spacer portion 120 extends away from the base 112. The corners and edges are curved to reduce stress on the rack 112 and to reduce the possibility of cracking. The curves at the tops of the wall portions 114 and the spacer portions 120 are convex in shape to facilitate the stacking of the rack 210 on top of the rack 110 during use.

The spacer portions 120 cooperate with the wall portions 114 that extend between the front end 112 a and the rear end 112 b to form concave channels 122. The concave channels 122 are each bounded by at least one spacer portion 120. Each channel 122 is sized to receive a roll of chub 104. When inserted into each channel 122, the chub 104 extends longitudinally between the front end 112 a and the rear end 112 b. The heights of the wall portions 114 and the spacer portions 120 are higher than that of the chub 104 that is inserted into the racks 110, 210

The sectional views of the racks 110, 210, shown in FIGS. 3 and 4, show that each of the wall portions 114 includes a cavity 124 formed therein. Each cavity 124 is sized and shaped to receive a substantial portion of a wall portion 114 from a similarly shaped rack. Similarly, each of the spacer portions 120 includes a cavity 126 formed therein. Each cavity 126 is sized and shaped to receive a substantial portion of a spacer portion 120 from a similarly shaped rack.

Referring to FIGS. 1 and 3, a vertical axis 118 extends from a geometric center of the first rack 110. When the second rack 210 is placed on top of the first rack 110, in either the first position or the second position, the vertical axis 118 extends through the geometric center of the second rack 210 as well. The assembly 100 is movable between the first position and the second position by rotating one of first rack 110 and the second rack 210 180 degrees about the vertical axis 118.

When in the first position, as shown in FIGS. 1 and 3, the base 112 of the second rack 210 is supported by the tops of the wall portions 114 and the spacer portions 120. The wall portions 114 and the spacer portions 120 engage the base 112 in a contact plane, with the lip 115 of the second rack 210 extending across the contact plane. Further, the tops of the wall portions 114 on the first rack 110 engage and interlock with the lip 115 of the second rack 210 to prevent the second rack 210 from sliding laterally off the first rack 110.

The racks 110, 210 are asymmetrical about a lateral plane that encompasses the vertical axis 118. The plane extends out of the plane of the paper of FIG. 3. The asymmetrical arrangement allows the base 112 of the second rack 210 to rest on the tops of the wall portions 114 and the spacer portions 120 when the first and second racks 110, 210 are in the first position. To support this asymmetrical arrangement, an odd number of rolls of chub 104 are able to be stored within each rack 110, 210.

Optionally, as shown in FIGS. 1 and 2, indicia 140 may be used to assist a user in quickly determining whether the second rack 210 is being placed on top of the first rack 110 in the proper position. The exemplary indicia 140 is in the form of a horizontal stripe located along at least one of the wall portions 114. When the first and second racks 110, 210 are in the first position, as shown in FIG. 1, the indicia 140 is visible only on the front end 112 a of rack 110, and not on rear end 112 b of rack 210, which is located directly over front end 112 a of first rack 110. When the first and second racks 110, 210 are in the second position, as shown in FIG. 2, the indicia 140 is visible on the front end 112 a of the first rack 110 and the front end 112 a of the second rack 120, which is located directly over the front end 112 a of first rack 110.

Optionally, although not shown, the wall portions 114 may include vertical corrugation to increase the vertical strength of each rack 110, 210. Preferably, the racks 110, 210, are constructed from a material that is not brittle and can maintain its integrity over a large number of thermal cycles. Such a material is a rubberized polyethylene, although an artisan will recognize that other suitable materials, including, but not limited to polycarbonate, polyester, polystyrene, polypropylene, ABS, or other suitable polymer resin material, may be used as well.

For health reasons, it is important that the racks 110, 210 not have any holes therein. After use, the racks 110, 210 are sanitized prior to reuse. Holes in the racks may allow water used during sanitization to adhere to the side walls of the holes, allowing bacteria to grow and forming a health hazard.

In use in a manufacturing plant (not shown), logs of chub 104 are placed in the first rack 110 such that the chub 104 extends between the front end 112 a and the rear end 112 b. In the present embodiment, up to five logs of chub 104 may be placed in the first rack 110. Similarly, up to five logs of chub 104 are placed in the second rack 210. The first rack 110 is placed on a pallet (not shown). The second rack 210 is placed on top of the first rack 110 such that the indicia 140 on only one of the first and second racks 110, 210 is visible from either the front end 112 a and the rear end 112 b. In this manner, the wall portions 114 and spacer portions 120 of the first rack 110 engage the bottom of the base 112 of the second rack 210 and support the second rack 210. The second rack 210 does not engage or press upon the chub 104 in the first rack 110. Additional racks (not shown) may be stacked upon the second rack 210 in a similar fashion, until a desired number of racks are stacked upon each other.

The pallet with the racks is then transported to a freezer, where the chub 104 is frozen. The configuration of the racks 110, 210 allows cold air to pass through the relatively flat region s 116 to flow between the racks 110, 210. Since the chub 104 in the first rack 110 does not support the second rack 210, the air can flow between the top of the chub 104 in the first rack 110 and the bottom of the base 112 of the second rack 210, enhancing the freezing process of the chub 104.

After the chub 104 is frozen, the pallet with the chub 104 is removed from the freezer and shipped to a sales destination, where the chub 104 is removed from the racks 110, 210 for sale. After all of the chub 104 is removed from the racks 110, 210, the racks can be sanitized according to known techniques. After sanitation, the racks 110, 210 are nested in the second position for transport back to the manufacturing plant. The nesting position is formed by rotating the second rack 210 180 degrees about the vertical axis 118 relative to the stacked position.

The first rack 110 is place on the pallet and the second rack 210 is placed on top of the first rack 110 such that the indicia 140 on both racks 110, 210 is visible from either the front end 112 a or the second end 112 b. The wall portions 114 of the first rack 110 fit into the cavities 124 of the second rack 210 and the spacer portions 120 of the first rack 110 fit into the cavities 126 of the second rack 210, as shown in FIG. 4. The volume 102 between the first rack 110 and the second rack 210 is substantially reduced, reducing shipping volume of the rack assembly 100 and decreasing shipping costs to return the rack assembly 100 back to the manufacturing plant.

Although the invention is illustrated and described herein with reference to a specific embodiment, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the invention. While a preferred embodiment of the invention has been shown and described herein, it will be understood that such embodiment is provided by way of example only. Numerous variations, changes and substitutions will occur to those skilled in the art without departing from the spirit of the invention. Accordingly, it is intended that the appended claims cover all such variations as fall within the spirit and scope of the invention.

What is claimed: 

1. A modular rack assembly for storing goods comprising: a first rack having: a base; a plurality of wall portions extending upwardly away from the base, wherein each of the plurality of wall portions is separated from an adjacent portion of the plurality of wall portions by a relatively flat region; and a lip extending around a perimeter of the base; and a second rack generally identical to the first rack, wherein, in a first position, the second rack is stackable on top of the first rack such that the first rack engages the base of the second rack in a region of contact defining a plane, and the lip of the second rack extends across the plane.
 2. The modular rack assembly according to claim 1, further comprising, when in the first position, a product disposed between the first base and the second base.
 3. The modular rack assembly according to claim 2, wherein the plurality of wall portions extend higher from the base than the product.
 4. The modular rack assembly according to claim 1, wherein, in the first position, each relatively flat region has a surface on the underside thereof adapted to individually contact the tops of the plurality of wall portions and each of the plurality of wall portions of the first rack is underneath and contacts one of the flat regions of the second rack and each of the flat regions of the first rack is underneath one of the plurality of wall portions of the second rack.
 5. The modular rack assembly according to claim 1, wherein the plurality of wall portions are tapered from wider at the base to narrower in a direction away from the base.
 6. The modular rack assembly according to claim 1, wherein the plurality of wall portions comprise a plurality of peripheral wall portions wherein, in the first position, the lip of the second rack extends over the plurality of peripheral wall portions such that the first rack interlocks with the second rack.
 7. The modular rack assembly according to claim 1, wherein the second rack is rotated 180 degrees to move between the first position and a second position, in which the second rack is nested on top of the first rack.
 8. The modular rack assembly according to claim 7, wherein, in the first position, the assembly has a first height and in the second position, the assembly has a second height lower than the first height.
 9. The modular rack assembly according to claim 7, wherein the first rack comprises first indicia on at least one of its plurality of wall portions and the second rack comprises second indicia on at least one of its plurality of wall portions such that, in the first position, only one of the first and second indicia is visible from any one direction and, in the second position, both of the first and the second indicia are visible from any one direction.
 10. The modular rack assembly according to claim 7, wherein, in the second position, the second rack is stackable on top of the first rack such that each of the plurality of wall portions of the first rack is insertable into an opening of a corresponding one of the plurality of wall portions of the second rack.
 11. The modular rack assembly according to claim 1, wherein each of the first rack and the second rack further comprises: a front end; a rear end; and a plurality of spacer portions extending away from the base between the front end and the rear end.
 12. The modular rack assembly according to claim 11, wherein the plurality of spacer portions extend perpendicularly to at least one of the plurality of wall portions.
 13. The modular rack assembly according to claim 11, wherein, in the first position, at least one of the spacer portions of the first rack engages the base of the second rack.
 14. The modular rack assembly according to claim 11, further comprising a plurality of concave portions extending between the front end and the rear end and bounded by one or more of the plurality of spacer portions.
 15. A modular rack assembly for storing goods comprising: a first rack having: a base; a plurality of wall portions extending upwardly away from the base, wherein each of the plurality of wall portions is separated from an adjacent portion of the plurality of wall portions by a relatively flat region; and a lip extending around a perimeter of the base; and a second rack generally identical to the first rack, wherein, in a first position, the second rack is stackable on top of the first rack such that the first rack engages the lip of the second rack.
 16. A modular rack assembly for storing goods comprising: a first rack having: a base; and a plurality of wall portions extending upwardly away from the base, wherein each of the plurality of wall portions is separated from an adjacent of the plurality of wall portions by a relatively flat region and wherein each of the plurality of wall portions includes convex tops; and a second rack generally identical to the first rack, wherein, in a first position, the second rack is stackable on top of the first rack such that at least one of the convex tops of the first rack engages the base of the second rack.
 17. The modular rack assembly according to claim 16, wherein, in the first position, the first rack interlocks with the second rack.
 18. The modular rack assembly according to claim 16, wherein each of the first rack and the second rack further comprises: a front end; a rear end; and a plurality of spacer portions extending away from the base between the front end and the rear end.
 19. The modular rack assembly according to claim 18, further comprising a plurality of concave portions extending between the front end and the rear end.
 20. A modular rack assembly comprising: a first rack having: a base; a plurality of wall portions extending upwardly away from the base, wherein each of the plurality of wall portions is separated from an adjacent portion of the plurality of wall portions by a relatively flat region and wherein each of the plurality of wall portions is tapered from wider at the base to narrower in a direction away from the base; a front end; a rear end; a plurality of spacer portions extending away from the base between the front end and the rear end, wherein the plurality of spacer portions extend perpendicularly to at least one of the plurality of wall portions; a plurality of concave portions extending between the front end and the rear end and bounded by one or more of the plurality of spacer portions; and a lip extending around a perimeter of the base; and a second rack, identical to the first rack, wherein, in a first position, the second rack is stackable on top of the first rack such that the first rack engages the base of the second rack in region of contact extending in a plane, and the lip of the second rack extends across the plane, and wherein the first rack comprises first indicia on at least one of its plurality of wall portions and the second rack comprises second indicia on at least one of its plurality of wall portions such that, in the first position, only one of the first and second indicia is visible from any one direction and, in the second position, both of the first and the second indicia are visible from any one direction.
 21. A method of transferring heat between a plurality of chub logs and a surrounding atmosphere comprising the steps of: providing a first rack having: a base; a plurality of wall portions extending upwardly away from the base, wherein each of the plurality of wall portions is separated from an adjacent of the plurality of wall portions by a relatively flat region; a front end; a rear end; a plurality of spacer portions extending away from the base between the front end and the rear end; a plurality of concave portions extending between the front end and the rear end and bounded by one or more of the plurality of spacer portions; and a lip extending around a perimeter of the base; loading the plurality of chub logs individually in the plurality of concave regions; placing a second rack, identical to the first rack, on top of the first rack such that the first rack engages the base of the second rack in a region of contact, forming a space between the base of the second rack and the chub logs; and exposing the product to the surrounding atmosphere to transfer heat between the chub logs and the surrounding atmosphere.
 22. The method according to claim 21, further comprising the step of allowing air to flow over the top of the chub logs. 